Hi to those who still lurk on the forums!
Its sad how socials have made forums redundant these days. I find socials very hard to document a build/share it with others
So this is basically a way for me to document each step of my build for myself.. but enjoy anyways
A bit of history with my van:
I bought the van around 12-13 years ago just as a random purchase. The car sat around ~130k kms, now sitting on around ~184k kms
White, F10a with a 4 speed in pretty good nick! Only thing aftermarket it came with was a little sound system
Fast forward to 2021/2022, no real major work was done in between then and now, but the van needed some TLC due to some surface rust, scratches and dents
This is the list of work so far: (29/03/2022)
Engine and transmission
- Full transmission rebuild - new synchros, bearings, seals etc.
- New Exedy clutch
- Machined flywheel
- New transmission mount
- Engine machined, re-bore (slight oversize), decked
- New pistons, rings, gaskets, seals
- Carby rebuilt
- New radiator + hoses + thermostat
- New headers + exhasut (to be fabricated)
- New coolant and fuel lines where required
Suspension, brakes and wheels
- Lowered springs
- Lowered blocks
- New brake master cylinder
- Watanabe 13x6
- New black wheel nuts
- New black tyre valves
Interior
- Everything else painted black
- Black roof carpet
- Fabricated roof supports
- Black door carpet
- New interior light cover
- New wooden steering wheel and boss kit (doesnt fit!)
- New carbon fibre gear knob
- Leather seats fitting to factory rails
- Kicker speakers
- JVC headunit
External and body
- New headlights
- New taillights
- New sliding door window metal inserts + rubber
- Closed door respray in white
- Rust repaired and treated
- New windshield
- Tint all around
Late 2021, I decided to start repairing some of the surface rust and getting ready for paint
Jezza's SK410 Van Build
My roof lining was sagging, and I had the roof "popping" in when the wind pressure was too much. The roof supports were slightly kinked, so decided to fabricate some bigger and better ones!
Was a massive pain trying to remove the foam backing stuck to the roof
I used some high temp adhesive (130*c) to stick the roof lining on
I have to mention a big thanks to my wife who calmed me down and helped me glue the lining on! It was not a fun job...
Was a massive pain trying to remove the foam backing stuck to the roof
I used some high temp adhesive (130*c) to stick the roof lining on
I have to mention a big thanks to my wife who calmed me down and helped me glue the lining on! It was not a fun job...
Last edited by jezzza on Tue Mar 29, 2022 2:10 pm, edited 1 time in total.
Fabricated a mount for the radiator to fit. It looks like the hoses should still fit *fingers crossed*
The inlet and outlet are a few cm to the passengers side. The stock shroud fits for now, but will need to make something custom to fit better
Im planning on make an air tunnel straight to the filter - hence the bracket design
The inlet and outlet are a few cm to the passengers side. The stock shroud fits for now, but will need to make something custom to fit better
Im planning on make an air tunnel straight to the filter - hence the bracket design
Mock up of seats (Hyundai i30) and steering wheel setup
The seats were fitted to stock rails. They sit higher than stock, which does feel a bit odd as you sit higher. But with the steering wheel + boss kit, the driving position is almost same distance as stock, just a little higher
The seats were fitted to stock rails. They sit higher than stock, which does feel a bit odd as you sit higher. But with the steering wheel + boss kit, the driving position is almost same distance as stock, just a little higher
Engine machined and being rebuilt - the machinist didnt have a tool small enough to bore!
We ran into lots of issues with the rebuild kit I bought.. the bearings didnt seem to be standard
Had to buy piston and rings because of it being bored Carrys massive clutch Painted the rocker cover in wrinkle black - came out really well
We ran into lots of issues with the rebuild kit I bought.. the bearings didnt seem to be standard
Had to buy piston and rings because of it being bored Carrys massive clutch Painted the rocker cover in wrinkle black - came out really well
Last edited by jezzza on Tue Mar 29, 2022 1:35 pm, edited 2 times in total.
Replaced the brake master cylinder due to leaking
I had to weld on a little tab for the proportioning valve <?> .. the blue thing. The overly expensive master cylinder didnt have the mounts for it
I didnt bother repainting the booster because its under the dash. and I was a bit concerned about overspray getting on the exterior of car
I had to weld on a little tab for the proportioning valve <?> .. the blue thing. The overly expensive master cylinder didnt have the mounts for it
I didnt bother repainting the booster because its under the dash. and I was a bit concerned about overspray getting on the exterior of car
My mirrors have deteriorated to a point of no return. I tried to refurbish them, but after sanding them I realise it jsut wasnt going to happen.
I purchased some retro style dome mirrors and will be installing them soon
Ive modelled up some mirror mounts and my bro in law 3d printed it for me Modelled up wiper covers
I purchased some retro style dome mirrors and will be installing them soon
Ive modelled up some mirror mounts and my bro in law 3d printed it for me Modelled up wiper covers
Putting back together the dash etc.
I refurbished the cluster plastic as was pretty scratched up. I used 1000/2000 grit wet sand, then sprayed over with clear - but failed!
I had to re-sand it down, repeat 1000/2000 sanding, and then polished with plasticx which came up way better